Insulating wall panel apparatuses, systems, and methods

ABSTRACT

Methods, systems, and apparatuses for an insulated wall panel. An embodiment of the insulated wall panel having an insulating layer with sheathing on one side and a plurality of studs on the other. Another embodiment of the insulated wall panel having a removable chase portion formed in an insulating panel.

FIELD OF THE INVENTION

This invention is related to building construction, and more particularly to the construction of insulating walls that may be prefabricated and may be for use as building exterior walls.

BACKGROUND OF THE INVENTION

Traditional exterior building walls are frequently constructed of solid masonry or wood framing with fascia such as brick, stucco, or siding on the exterior side and plaster or wall board on the interior side. Insulation, such as fiberglass insulation if frequently positioned between the wood framing of such walls. Each of those construction methods are typically performed on the building site sequentially and frequently by different trades people. Thus, such construction can be time consuming and expensive. Such construction furthermore provides limited insulation value, often in the range of R-11 to R-17, lacks effective radiant barriers, and permit air infiltration through the walls.

Accordingly, there is a need for a pre-manufactured wall that is quickly installed, there is a need for a pre-manufactured wall that may be installed by a single crew of trades people, there is a need for a pre-manufactured wall that is highly insulating, there is a need for a pre-manufactured wall that includes an effective radiant barrier, and there is a need for a pre-manufactured wall that minimizes air infiltration.

SUMMARY OF THE INVENTION

The present invention is directed to systems, methods and apparatuses for insulating wall panels. In accordance with one form of the present invention, there is provided an insulating wall panel having sheathing, an insulating layer adjacent the sheathing, and a plurality of studs adjacent the insulating layer opposite the sheathing.

In another embodiment, the insulated wall panel includes sheathing, a plurality of studs adjacent the insulating layer opposite the sheathing, and an insulating panel disposed between two of the plurality of studs, the insulating panel having a removable chase portion formed therein.

In yet another embodiment, the insulated wall panel includes sheathing having a first side and a second side, an insulating material having a first side attached continuously to the first side of the sheathing and a second side, a plurality of structural support members adjacent the second side of the insulating material, and a radiant barrier adjacent the second side of the sheathing;

Accordingly, the present invention provides solutions to the shortcomings of prior wall systems and methods. Those of ordinary skill in wall construction will readily appreciate, therefore, that those details described above and other details, features, and advantages of the present invention will become further apparent in the following detailed description of the preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, wherein like reference numerals are employed to designate like components, are included to provide a further understanding of insulating wall apparatuses, systems, and methods, are incorporated in and constitute a part of this specification, and illustrate embodiments of a insulating wall apparatuses, systems, and methods that together with the description serve to explain the principles of insulating wall apparatuses, systems and methods.

Various other objects, features and advantages of the invention will be readily apparent according to the following description exemplified by the drawings, which are shown by way of example only, wherein:

FIG. 1 illustrates a perspective view of an embodiment of an insulated wall panel;

FIG. 2 illustrates a top view of the foundation wall of FIG. 1;

FIG. 3 illustrates a side view of the foundation wall of FIGS. 1 and 2; and

FIG. 4 illustrates a partial cut-away detail of an embodiment of an insulated wall panel to floor structure interconnection.

DETAILED DESCRIPTION

Reference will now be made to embodiments of insulated wall panel apparatuses, systems, and methods, examples of which are illustrated in the accompanying drawings. Details, features, and advantages of the insulated wall panel apparatuses, systems, and methods will become further apparent in the following detailed description of embodiments thereof.

As used herein, an “insulated wall panel” refers to an insulated panel used to construct a building. An insulated wall panel may comprise a portion or all of a residential or commercial building wall installed mostly or completely above grade. The insulated wall panel may include one or more components described herein with respect to insulated wall panel, such as, for example, support elements, elements that secure or facilitate the securing of portions of the insulated wall panel to other panels or other structures, and/or elements that accommodate the inclusion of elements of a structure, such as, for example, doors, windows, driveways, brick and other facades, supports such as support beams, the extension of wiring or pipes through the insulated wall panel, and/or other elements.

Any reference in the specification to “one embodiment,” “a certain embodiment,” or a similar reference to an embodiment is intended to indicate that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such terms in various places in the specification do not necessarily all refer to the same embodiment. References to “or” are furthermore intended as inclusive, so “or” may indicate one or another of the ored terms or more than one ored term.

FIG. 1 illustrates an insulated wall panel 100 having a base plate 102, a header plate 104, a plurality of studs 106, a plurality of insulating panels 108, an insulating layer 110, a radiant barrier 112, or emissivity barrier, and sheathing 114.

The base plate 102 may be of any desired material suitable for building construction, including wood, steel, or concrete. The base plate may furthermore set on or be attached to a footer, foundation wall, or other structure.

The header plate 104 may also be of any desired material suitable for building construction, including wood, steel, or concrete. The base plate may furthermore support another structure such as, for example, another wall or a roof structure.

The studs 106 may be of any desired material suitable for building construction, including wood, steel, or concrete. The studs 106, base plate 102 and header plate 104 may furthermore be formed in any desired size, such as a nominal 2×4 or 2×6 dimension, and in any desired length. Alternately, any structural support member or members may be used in place of the studs. The structural support members or studs may furthermore provide one or more of an axial, shear, and lateral load bearing aspect to the insulated wall panel 100.

In traditional walls, the studs create an undesirable thermal break since insulation is placed between the studs 106. In embodiments of the present insulated wall panel 100, the insulating layer 110 is continuously unbroken by studs 106 or other support members. The studs 106 or support members forming a support structure are situated on one side of the insulating layer 110 and the sheathing 114 on the other side of the insulating layer 110. In embodiments, the insulating layer 110 may be a structural element to which the support structure and the sheathing 114 may be attached by adhesives or otherwise. In other embodiments, fasteners may extend from the sheathing 114, through the insulating layer 110 into the support structure to provide rigidity to the insulated wall panel 100 or otherwise to retain the insulated wall panel 100 components in a unit.

The insulating panels 108 and insulating layer 110 may be formed together as a single unit or separately as desired. The insulating panels 108 may be planar insulating elements and may also provide structural support to the insulated wall panel 100. For example, the insulating panels 108 and insulating layer 110 may be formed of any insulating material including, for example, fire retardant polystyrene foam or another foam material. The insulating panels 108 and insulating layer 110 may furthermore be formed in any desired thickness, such as eight inch or ten inch thickness. The thickness may furthermore be determined based on the location of the building such that a building constructed in a cold climate may be constructed with a thicker insulating panel 108 or insulating layer 110.

FIG. 2 illustrates a top view 120 of the foundation wall 100 of FIG. 1 without the header plate 104 attached thereto. FIG. 2 illustrates an embodiment in which the insulating panels 108 and insulating layer 110 are formed together as an insulating base 121. The insulating base 121 may be cut or otherwise formed to include recesses 122 in which the studs 106 may be placed.

FIG. 3 illustrates a side view 150 of the foundation wall 100 of FIGS. 1 and 2 with the base plate 102, header plate 104, and studs 106 attached thereto. An embodiment of the foundation wall 100 includes a header recess 152 in which the header plate 104 may be disposed and a bottom plate recess 154 in which the base plate 102 may be disposed. Studs 106 may be fastened to the base plate 102 or header plate prior to or after placement in the insulating base 121.

Referring again to FIG. 2, one or more removable chase portions 124 may be formed in the insulating panels 108. In an embodiment, removable chase portions 124 of the insulating panels 108 are formed so they may be simply removed to create a chase (not shown) in the insulated wall panel 100. For example, where an insulating panel 108 is separate from the insulating layer 110, a parallel cut 126 may be placed in a vertical line parallel to the studs 106 through the insulating panel 108 so that the removable chase portion 124 of the insulating panel 108 may be grasped and pulled from the remainder of the insulating panel 108 along the parallel cut 126 to expose a chase (not shown) where the removable chase portion 124 of the insulating panel 108 was removed.

In another embodiment where the insulating panels 108 are formed with the insulating layer 110, a perpendicular cut 128 may be placed perpendicular to a stud 106 through the chase portion 124 of the insulating panel 108 to separate the chase portion 124 of the insulating panel 108 from the insulating layer 110 or divide the insulating panel 108. A parallel cut 126 may also be placed in a vertical line through the removable chase portion 124 of the insulating panel 108 so that the removable chase portion 124 of the insulating panel 108 may be grasped and pulled from the remainder of the insulating panel 108 along the vertical line to expose a chase where the removable chase portion 124 of the insulating panel 108 was removed.

It should be recognized that one or more parallel cuts 126 may be used to form the removable chase portion 124. In an embodiment, a single parallel cut 126 is created adjacent a stud 106 to form a chase adjacent the stud 106. The parallel cuts 126 may furthermore be positioned to create a chase of a desired width, such as the width of a standard wall outlet box. Similarly, the perpendicular cut 128 may be positioned at any desired depth from an inside surface 130 of the insulating panel 108 to create a chase of a desired depth and maximize the thickness of the insulating panel 108 to maximize the insulating property of the insulated wall panel 100.

It should also be recognized that the parallel cut 126 or the perpendicular cut 128 may be continuous, thus relying on friction to retain the removable chase portion 124 in the insulating panel 108 until removal of the removable chase portion 124 from the insulating panel 108 is desired. Alternately, the parallel cut 126 or the perpendicular cut 128 may include a series of linear cuts separated by uncut portions so that the uncut portions of the removable chase portion 124 may be cut or torn to remove the removable chase portion 124.

The sheathing 114 may be plywood, pressed wood board or any type of sheathing desired. The sheathing 114 may be attached to the insulating layer 110 by glue, such as a polyurethane adhesive or a construction adhesive, or otherwise as desired. The radiant barrier 112 may be a reflective insulation, for example, carrying a thin layer of aluminum, Mylar, or another reflective material. The radiant barrier 112 may also be attached to the sheathing 114 opposite the insulating layer 110 by glue or as desired.

Screws or other fasteners 130 may be placed through the sheathing 114 and the insulating layer 110 into the studs 106, the header plate 104, or the base plate 102. The screws or other fasteners 130 may be placed after the radiant barrier 112 and thus pass through the radiant barrier 112 as well as the sheathing 114 and the insulating layer 110.

Such a construction, where studs 106, chases and the like are built into the insulating portions 108 and 110 of the insulated wall panel 100, may also permit the insulated wall panel 100 to be thinner than previous highly insulating walls.

Referring again to FIG. 3, one or more removable chase portions 124 may be positioned horizontally in the insulating panels 108. Such horizontal removable chase portions 124 may be removed from the insulating panels 108 to provide an opening in the wall for any desired purpose including, for example, the insertion of piping or wire.

FIG. 4 illustrates a partial cut-away detail 180 of an embodiment of an insulated wall panel 100 to floor structure 182 interconnection. In traditional construction, walls are normally set on floors and air infiltration and heat transfer can be problems at the connection area between the wall and the uninsulated, exposed portion of the floor structure. Accordingly, the embodiment illustrated in FIG. 4 has been designed to extend the insulating layer 110 along the floor structure 182 and provide a long joint 183 that can be filled to prevent or minimize air infiltration and heat transfer. For example, insulating material may be placed between the insulated wall panel 100 and the support structure 184 or floor structure 182 to minimize air infiltration or heat transfer in the area where the insulated wall panel 100 is supported. The support structure 184 may furthermore be any support structure 184 such as, for example, a foundation wall or a lower floor wall.

In the embodiment illustrated in FIG. 4, the floor structure 182 is set or constructed to partially rest on a support structure 184 such as a footer, foundation wall, or an insulated wall panel 100. The insulated wall panel 100 to be set on the floor structure 182 is notched 186 from its inner surface 187. The insulated wall panel 100 may furthermore be constructed having two base plates 102 a support structure base plate 188 and a floor base plate 190 or may be constructed with a single base plate 102 that sets on the floor structure 182. In an embodiment having two base plates 188 and 190, the support structure base plate 188 is placed on the support structure 184 and the floor base plate 190 is placed on the floor structure 182.

The insulating wall panels 100 can be used as exterior, above grade walls for commercial and residential buildings. The insulating wall panels 100 can be manufactured in any size, such as for example the size of a side of a house.

In an embodiment, an insulating wall panel 100 is manufactured in an eight foot by fifty foot section. Holes are cut in the insulated wall panel 100 to create openings desired in a side of a house, such as openings to a accommodate windows and doors. The insulated wall panel 100 is then set on a support structure, such as a footer, foundation wall, or another insulated wall panel 100. Additional insulated wall panels 100 are then set to form all of the exterior, above grade walls of the house. Adjacent insulated wall panels 100 are then attached to one another to form the perimeter of the house.

Such insulated wall panels 100 may be manufactured in a manufacturing facility, transported to a building site, and set in place using a crane or other machinery.

While specific embodiments of the invention have been described in detail, it should be appreciated by those skilled in the art that various modifications and alternations could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements, apparatuses, systems, and methods disclosed are meant to be illustrative only and not limiting as to the scope of the invention. 

1. An insulated wall panel, comprising: sheathing; an insulating layer adjacent the sheathing; and a plurality of studs adjacent the insulating layer opposite the sheathing.
 2. The insulated wall panel of claim 1, further comprising a header plate attached to the plurality of studs.
 3. The insulated wall panel of claim 1, further comprising a base plate attached to the plurality of studs.
 4. The insulated wall panel of claim 3, wherein the insulating layer and the sheathing extend past the base plate.
 5. The insulated wall panel of claim 3, wherein, when installed, the base plate is set on a top of a floor structure and the insulating layer and sheathing extend along an edge of the floor structure.
 6. The insulated wall panel of claim 1, further comprising an insulating panel disposed adjacent the insulating layer and between two of the plurality of studs.
 7. The insulated wall panel of claim 6, wherein the insulating panel is formed with the insulating layer.
 8. The insulated wall panel of claim 6, further comprising a removable chase portion formed in the insulating panel.
 9. The insulated wall panel of claim 8, wherein the removable chase portion is removed to form a chase in the insulated wall panel.
 10. The insulated wall panel of claim 1, further comprising a fastener disposed through the sheathing and the insulating layer and extending into one of the plurality of studs.
 11. The insulated wall panel of claim 1, wherein the sheathing has a first side and a second side and the insulating layer is adjacent the first side of the sheathing, further comprising a radiant barrier adjacent the second side of the sheathing.
 12. An insulated wall panel, comprising: sheathing; a plurality of studs adjacent the insulating layer opposite the sheathing; and an insulating panel disposed between two of the plurality of studs, the insulating panel having a removable chase portion formed therein.
 13. The insulated wall panel of claim 12, wherein the removable chase portion is separated from the insulating panel by at least one cut.
 14. The insulated wall panel of claim 12, wherein the removable chase portion further includes a depression and the removable chase portion is separated from the insulating panel by engaging the depression and pulling the removable chase portion from the insulating panel.
 15. The insulated wall panel of claim 12, wherein the sheathing has a first side and a second side and the insulating layer is adjacent the first side of the sheathing, further comprising a radiant barrier adjacent the second side of the sheathing.
 16. An insulated wall panel, comprising: sheathing having a first side and a second side; an insulating material having a first side attached continuously to the first side of the sheathing and a second side; a plurality of structural support members adjacent the second side of the insulating material; and a radiant barrier adjacent the second side of the sheathing.
 17. The insulated wall panel of claim 16, further comprising a base plate attached to the plurality of studs.
 18. The insulated wall panel of claim 17, wherein the insulating layer and the sheathing extend past the base plate.
 19. The insulated wall panel of claim 16, further comprising an insulating panel disposed adjacent the insulating layer and between two of the plurality of studs.
 20. The insulated wall panel of claim 19, further comprising a removable chase portion formed in the insulating panel. 